Web frame

ABSTRACT

The web frame is a bonded assembly of panels and porous blanket layers, separated by an arrangement of isolated spacers. The panels and spacers are covered with a bonding means. A coating covers inner surfaces of the panels and spacers. The porous blanket is compressed and pinned between these panels, by spacers that are arranged as isolated nodes or columns The spacers have sharpened ends that penetrate the blanket and connect with the opposing panel. The web frame assembly provides thermal and sound insulation for buildings and other solid objects. These web frames are lightweight, durable, and permeable. Capillaries and passages throughout the panels and fibers of the blanket allow passage of moisture and air, thereby assisting in the management of condensation within the web frame.

This application is a continuation application of U.S. patentapplication Ser. No. 15/099,416, filed on Apr. 14, 2016, which in turnclaims priority under U.S. Pat. No. 9,315,988 issued on Apr. 19, 2016and filed on Oct. 20, 2014, which in turn claims priority under 35U.S.C. § 371 to application no. PCT/AU2013/000476, filed on May 10,2013, and the contents of all of the applications are herebyincorporated by reference in their entirety.

TECHNICAL FIELD

The invention relates to a multi layer web frame that attaches to awall, floor, ceiling or roof of a building or solid object. Theinvention provides thermal and sound insulation while assisting themanagement of condensation within the frame. The invention also relatesto a method of assembling the items that make the multi-layer web frame.

BACKGROUND ART

It is known to those who are familiar with frames and panels applied tobuildings as cladding, lining or cavity panels, that these panels have aprotective covering which seals the panels from water. However suchsealants create an impervious surface which prevents moisture fromescaping from within or passing through the panels. Absence ofcapillaries through these panels prevents the panel from breathing,resulting in an accumulation of moisture.

In current art, panels and impervious insulation assemblies are placedwithin wall cavities where condensation accumulates undetected in theearly life of the building. Consequently, the trapped condensationcauses dampness in the adjacent frames leading to buildingdeterioration.

Accumulation of condensation also provides moisture for moss and mildewto grow. These growths are considered major health risks to inhabitantsof buildings. To compensate for this moisture accumulation, existing artincludes are a number of add-on processes that include the creation ofadditional escape channels, using battens and furring members behind thepanels. These additional processes require skilled labour, project timeand costs. These add-on channels are subject to blockage fromconstruction material and waste.

It is known to those who are familiar in the art of covering buildingsand other objects that materials should be easy to handle. However, manyof these existing panel systems are heavy, requiring expensive liftingapparatus to apply them to a building.

Existing composite panel systems that use insulation layers betweenpanels, fail to provide sufficient passages within the assembly for airor moisture to pass. This lack of ventilation causes condensation.

Existing insulation systems place a metallic reflective film within awall cavity to reflect heat back towards the cavity. In suchcircumstances, the air in the cavity gains heat which is reflected backinto the outer wall material—the main source of heat initially. Thisouter wall material in turn radiates heat back into the cavity. Thisheat compounding process continues with a resulting heat gain in thecavity air, which has no ventilation. This whole process illustrates theinadequate insulation of such art.

Existing bulk insulation products are often poorly supported withinexisting insulating systems. The lack of adequate and enduring supportof the bulk insulation results in the fibres sagging, which eventuallyleaves a thick collapsed layer near the base of the panel and thin layerof bulk insulation near the top of the panel. The thin layer hasconsiderably reduced capacity of insulation compared with the originalcapacity, leading to reduced heat and sound insulation after anindefinite period.

Any discussion of documents, acts, materials, devices, articles or thelike which has been included in the present specification is solely forthe purpose of providing a context for the present invention. It is notto be taken as an admission that any or all of these matters form partof the prior art base or were common general knowledge in the fieldrelevant to the present invention as it existed before the priority dateof each claim of this application.

SUMMARY OF THE INVENTION

The invention describes a web frame which consists of an assembly ofmaterials that provide thermal and sound insulation, and providepassages for moisture and air to permeate. The web frame has an outerpanel bonded coextensively to a first web-sandwich.

In a further embodiment of the web frame, an outer panel is bondedcoextensively to a first web-sandwich, wherein the first web-sandwich isbonded coextensively to one or more web-sandwiches in series. Eachweb-sandwich comprises an inner panel, means bonding, surface coatingson the inner surfaces of the panels, an assembly of spacer items thatseparate opposing panels, and a blanket layer confined to a finite spacebetween opposing panels.

A blanket layer is pressed between opposing panels, pinned to theopposing panel by an assembly of spacer items, which prevent the blanketlayer from sagging.

The spacer items have sharpened ends that penetrate the blanket layerthereby obtaining a positive connection between spacer items and theopposing panel.

The spaces between strands and openings within the porous blanket layerprovides a drainage passage within the blanket layer that allowsmoisture to pass through the web frame. The space ranges from 0.01 mm to2 mm, but preferably 0.02 mm space.

In one embodiment of a web-sandwich the blanket layer is an open-weavedbulk insulation.

In a further embodiment of a web-sandwich the blanket layer is a wovenfabric.

In a further embodiment of a web-sandwich the blanket layer is anon-woven fabric or batt with openings throughout the blanket layer.

In a further embodiment of a web-sandwich the blanket layer is amulti-layered mesh.

The inner surfaces of all panels are bonded to and covered with acoating or film, being selected from one or more than one of thefollowing group:

(i) metallic reflective film;

(ii) metallic reflective coating;

(iii) weatherproof coating; and

(iv) fire-retardant coating.

In one particular embodiment of the web frame, the inner surfaces of thepanels are coated with metallic reflective coating, which providesthermal insulation by reflection. The limited amount of heat emittedthrough these reflective surfaces heats the air in the confined spacebetween panels, wherein warm air dissipates through the passages of theadjacent porous blanket.

In a further embodiment of the invention, fine capillaries existthroughout the panels and surface coverings, the capillaries providingpassages through which air and moisture may pass.

In a further embodiment of the invention the panels, spacer items, meansbonding, surface coverings and blanket layers are selected from a groupof lightweight materials, and assembled to form a lightweight web frame.This lightweight web frame is easy to handle, and reduces applicationcosts

In a further application of the invention, the web frame can be appliedto a wall, facade, ceiling, floor, or a roof.

In further application of the invention, the web frame functions as astructural, stand alone wall.

The outer panel is made from materials that are durable and resilientand selected from one or more than one of a group of materialscomprising:

(i) reinforced concrete;

(ii) autoclaved aerated concrete;

(iii) polyurethane;

(iv) polystyrene;

(v) polypropylene;

(vi) plywood;

(vii) fibre cement;

(viii) metal sheeting;

(ix) particle board;

(x) cardboard; and

(xi) timber.

The outer panel is typically 2 mm to 200 mm thick, and most preferably 5mm to 20 mm thick.

The inner panels are made from materials that are durable, resilient andflexible, that are materials selected from one or more than one of agroup comprising:

(i) reinforced concrete;

(ii) autoclaved aerated concrete;

(iii) polyurethane;

(iv) polystyrene;

(v) polypropylene;

(vi) plywood;

(vii) fibre cement;

(viii) metal sheeting;

(ix) particle board;

(x) cardboard; and

(xi) timber

The inner panels are typically 2 mm to 150 mm thick, and most preferably5 mm to 20 mm thick.

The opposing panels are spaced apart by a series of spacer-nodes thatare arranged in an assembly of spacer items, wherein these spacer-nodesare independent and separated. The separation of these spacer-nodes istypically in a range from 20 mm to 200 mm, and most preferably 50 mmseparation.

The spacer-nodes protrude from the adjacent inner panel on which theyare formed. The node protrusion dimension ranges from 2 mm to 50 mm, buttypically protrude 20 mm.

In another configuration, the opposing panels are spaced apart by aseries of spacer-columns arranged in such an assembly that theseindependent spacer-columns are separated from each other. The separationbetween these spacer-columns is typically in a range from 20 mm to 200mm, and most preferably 50 mm separation.

The spacer-columns butt onto and are positioned between opposing panels,the spacer-columns each being isolated items not formed with any panel.The spacer-column length ranges from 2 mm to 50 mm, but typically 20 mm.

The blanket layer is confined to a defined space between opposingpanels. The blanket layer is compressed to a thickness ranging from 2 mmto 50 mm, but typically 20 mm thick.

The web frame has a cover-sheet attached to its outer edges, around theperimeter of the web frame. The cover-sheet is made from material thatis durable, flexible, weatherproof, fire-retarding and thermallyreflective.

The cover-sheet extends beyond the perimeter of the web frame, whereinthe extended portion of the cover-sheet is folded over and attached tothe outer edges of the web frame around the perimeter.

The cover-sheet protects the outer edges of the web frame from access ofmoisture, pollution and external heat.

It should be understood that words used in this application have thefollowing meaning:

(i) web-sandwich, means a laminate of a panel, blanket, spacers, andsurface coverings bonded together coextensively to create a compressedsandwich of defined building items;

(ii) web frame, means an assembly of an outer panel bonded to aweb-sandwich that may be further bonded to another web-sandwich tocreate a frame;

(iii) nodes, means material that is formed on the surface of an innerpanel and protrudes from the face of the panel, wherein the node acts asa spacer between opposing panels; wherein the node is separated fromadjacent nodes, and may have a variety of shapes;

(iv) spacer-columns are isolated items of material not formed with anypanel, wherein the spacer-columns are made in a variety of shapes andseparate opposing panels;

(v) capillaries, means the fine air passages throughout a material;

(vi) Passages, are finite openings throughout the blanket layers thatpermit air and moisture to permeate;

(vii) Cover-sheets, are defined as sheets or webbing of a flexible,resilient permeable material that extends from the web frame and foldsover to cover the outer edges of the web frame.

BRIEF DESCRIPTION OF THE DRAWINGS

Specific embodiments of the invention will now be described by exampleonly and with reference to the accompanying drawings in which:

FIG. 1 shows a first embodiment of a web frame with a web-sandwichhaving a formed inner panel;

FIG. 2 shows a second embodiment of a web frame with an alternative ofweb-sandwich having a planar inner panel, and spacer-columns;

FIG. 3 shows a third embodiment of a web frame formed with two types ofweb-sandwich, one with a formed inner panel the other with a planarpanel and spacer-columns;

FIG. 4 shows a fourth embodiment of a web frame formed with two types ofweb-sandwiches having capillaries throughout;

FIG. 5 shows a series of shapes that describe the spacers; and

FIG. 6 shows a cover-sheet that wraps over the exposed edges of a webframe.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Referring to FIG. 1 wherein web frame 23 comprising an outer panel 10whose thickness ranges between 2 mm and 200 mm, and in the particularembodiment the outer panel 10 is bonded coextensively to a web-sandwich22 comprising an inner panel 11, a defined open zone 13 in which ablanket layer 14 is confined, with spacer-nodes 15, surface covering 17and means bonding 18.

The surface covering 17 is bonded to all inner surfaces by a bondingmeans 18. The blanket 14 is pinned and compressed between the outerpanel 10 and the inner panel 11 by means of an assembly of spacer-nodes15 arranged as isolated nodes separate from each other and formed on thesurface of the inner panel 11.

The blanket layer 14 is made of one or more than one of a selection ofmaterials that are porous, flexible, durable, and resilient.

The thickness of the compressed blanket 14 ranges between 2 mm and 50mm, but preferably 20 mm.

The spacer nodes 15 have sharpened tips 20 that penetrate the blanket 14and contact the opposing panel. The sharpened tips 20 of thespacer-nodes 15 have bonding means 19 at each tip to bond thespacer-node 15 to the outer panel 10.

The blanket 14 consists of a porous material with voids and passages 24between fibres and strands of the blanket layer 14, wherein these voids24 allow air and moisture to pass throughout the blanket layer 14. Thesevoids and passages 24 have a diameter in the range of 0.01 mm and 2 mm,but preferably 0.02 mm diameter.

Referring to FIG. 2 where a web frame 27 comprising an outer panel 10whose thickness is in the range of 2 mm and 200 mm, and in theparticular embodiment the outer panel 10 is bonded coextensively to aweb-sandwich 26 comprising an inner panel 12, a defined zone 13 in whicha blanket layer 14 is confined, spacer-columns 16, surface coverings 17and means bonding 18.

The surface covering 17 is bonded to all inner surfaces of all panels bya bonding means 18.

The blanket 14 is pinned and compressed between the outer panel 10 andthe inner panel 12 by means of an assembly of spacer-columns 16 arrangedas isolated columns separate from each other and located in a planeparallel to and between opposing panels. The thickness of the compressedblanket layer 14 ranges between 2 mm and 50 mm, but preferably 20 mmthick.

The spacer-columns 16 have sharpened tips 21 that penetrate the blanket14 and contact the opposing panel. The sharpened tips 21 of thespacer-columns 16 have bonding means 19 at each tip 21 to bond withopposing panels.

The blanket layer 14 consists of a porous material having voids andpassages 24 between fibres and strands of the blanket 14, wherein thesepassages 24 allow air and moisture to permeate through the blanket layer14.

These voids and passages 24 have a diameter of openings or gaps betweenfibres in a range of 0.01 mm and 2 mm, but preferably 0.02 mm diameter.

FIG. 3 illustrates a combination of an outer panel 10 and two differentweb-sandwiches 22 and 26. In a further embodiment of the web frame 28,the outer panel 10 is bonded to and is coextensive with web-sandwich 26as described in FIG. 2, wherein a further web-sandwich 22, as describedin FIG. 1, is bonded to the first web-sandwich 26.

FIG. 4 shows a further embodiment of a web frame 31, wherein finecapillaries 25 permeate the outer panel 10 and the web-sandwiches 29 and30, and allow moisture and air through the web frame 31. The diameter ofsuch capillaries 25 are in the range of 0.01 mm and 2 mm, and are spacedapart where such spacing ranges from 5 mm to 100 mm between adjacentcapillaries.

FIG. 5 illustrates the various alternative shapes of spacer-node 15 andspacer-columns 16, wherein the shapes shown comprise:

(i) Cylinder with sharpened ends 20 for spacer-node, and 21 forspacer-column;

(ii) Sphere with sharpened ends 20 for spacer-node, and 21 forspacer-column;

(iii) Ball with sharpened ends 20 for spacer-node; and 21 forspacer-column;

(iv) Cone with sharpened ends 20 for spacer-node, and 21 forspacer-column;

(v) Ring with sharpened ends 20 for spacer-node, and 21 forspacer-column; and

(vi) Block with sharpened ends 20 for spacer-node, and 21 forspacer-column.

The sharpened ends 20 and 21 respectively, penetrate the blanket layer14 and pin the blanket to the opposing panel, preventing the blanket 14from sagging.

FIG. 6 illustrates a cover-sheet 32 which extends beyond the web frame31, wherein the cover-sheet folds over the outer edge of the web frame31 and is attached to the outer edge of web frame 31, thereby thecover-sheet 32 protects the outer edges of web frame 31 from weather,pollution, and thermal fluctuations.

The cover-sheet 32 is permeable with pin-hole penetrations 33 throughoutthe cover-sheet 32, wherein these pin-hole penetrations 33 allowmoisture to permeate through the cover sheet 31.

The invention claimed is:
 1. A web frame, being an assembly of stacked,bonded materials, the web frame comprising: an outer panel; and a websandwich comprising: an inner panel having an inner surface and an outersurface, the inner panel disposed parallel to and apart from the outerpanel to form an open space therebetween, wherein the outer panel has aninward surface adjacent the open space; a plurality of spacers in theopen space between the inner panel and the outer panel to maintain theopen space therebetween to allow moisture and air through the web frame,wherein each of the plurality of spacers is isolated and separated fromeach other; wherein the spacers engage with the panels opposite eachother; wherein the spacers are selected from a group comprising: (i)spacers formed with the inner panel and extending through the open spaceto engage with the outer panel; and (ii) spacers attached to the innerpanel and extending through the open space to engage with the outerpanel, wherein the web frame is a structural stand-alone wall.
 2. Theweb frame according to claim 1, wherein the inner panel and outer panelhave a plurality of fine capillaries extending therethrough, theplurality of fine capillaries allowing moisture and air to permeate. 3.The web frame according to claim 1, wherein the inner and outer panelsare comprised of materials selected from the group of materialsconsisting of reinforced concrete, autoclaved aerated concrete, plywood,fiber cement, metal sheeting, particle board, cardboard, and timber. 4.The web frame according to claim 1, further comprising a blanket layerdisposed in the space between the inner panel and the outer panel,wherein the blanket layer is pinned to the inner surface of the outerpanel by the plurality of spacers.
 5. A web frame, being an assembly ofstacked, bonded materials, the web frame comprising a plurality ofweb-sandwiches, and an outer panel, each of the plurality ofweb-sandwiches comprising: an inner panel having an inner surface and anouter surface, the inner panel disposed parallel to and apart from apanel opposite the inner panel to form an open space therebetween,wherein the panel opposite the inner panel has an inward surfaceadjacent the space; a plurality of spacers in the open space between theinner panel and the panel opposite the inner panel to maintain the spacetherebetween to allow moisture and air through the web frame, whereineach of the plurality of spacers is isolated and separated from eachother; wherein the spacers are engaged with panels opposite each other;wherein the outer panel is the panel opposite the inner panel of a firstweb-sandwich; wherein the first web-sandwich is one of the plurality ofweb-sandwiches; wherein the first web-sandwich is in series with theremaining web-sandwiches of the plurality of web-sandwiches; and whereinthe panel opposite the inner panel of one of the remainingweb-sandwiches of the plurality of web-sandwiches is the inner panel ofa preceding web-sandwich; wherein spacers are selected from the groupcomprising: (i) spacers formed with the inner panel and extendingthrough the open space to engage with the panel opposite the innerpanel; and (ii) spacers attached to the inner panel and extendingthrough the open space to engage with the panel opposite the innerpanel; and wherein the web frame is a structural stand-alone wall. 6.The web frame according to claim 5, wherein the inner panel and panelopposite the inner panel have a plurality of fine capillaries extendingtherethrough, that allow moisture and air to permeate.
 7. The web frameaccording to claim 5, wherein the outer panel and inner panels arecomprised of materials selected from the group of materials consistingof reinforced concrete, autoclaved aerated concrete, plywood, fibercement, metal sheeting, particle board, cardboard, and timber.
 8. Theweb-frame according to claim 5, further comprising a blanket layerdisposed in the space between the inner panel and the panel opposite theinner panel, wherein each blanket layer is pinned to the inner surfaceopposite each inner panel by the plurality of spacers.
 9. A web frame,being an assembly of stacked, bonded materials, the web framecomprising: an outer panel; and a web sandwich comprising: an innerpanel having an inner surface and an outer surface, the inner paneldisposed parallel to and apart from the outer panel to form an openspace therebetween, wherein the outer panel has an inward surfaceadjacent the open space; a plurality of spacers in the open spacebetween the inner panel and the outer panel to maintain the open spacetherebetween to allow moisture and air through the web frame, whereineach of the plurality of spacers is isolated and separated from eachother; wherein the inner panel and outer panel have a plurality of finecapillaries extending therethrough, the plurality of fine capillariesallowing moisture and air to permeate therethrough and the web frame isa structural stand-alone wall; wherein the spacers engage with thepanels opposite each other; wherein the spacers are selected from agroup comprising: (i) spacers formed with the inner panel and extendingthrough the open space to engage with the outer panel; and (ii) spacersattached to the inner panel and extending through the open space toengage with the outer panel.